LAND ROVER DEFENDER 1996 Workshop Manual

57STEERING
8
OVERHAUL 84.Refit locknut and tighten.
NOTE: It is important steering box is
centralised before any adjustments are
made.
85.Check maximum rolling torque one and a quarter
turns either side of centre position, using a
torque wrench and spline socketLRT-57-025.
Rotate adjuster screw to obtain across centre
torque of 0.34 Nm plus torque figure at one and
a quarter turns. Tighten adjuster locknut to
60
Nm (44 lbf/ft).
Adjusting rack adjuster.
86.Turn in rack adjuster to increase figure
measured in instruction 85. by 0.23 - 0.34 Nm.
The final figure may be less, but must not
exceed 1.35 Nm.
87.Lock rack adjuster in position with grub screw.
Tighten to
5 Nm (4 lbf/ft).
Torque peak check
With input shaft rotated from lock to lock, rolling
torque figures should be greatest across centre
position and equally disposed about centre position.
The condition depends on value of shimming fitted
between valve and worm assembly inner bearing cup
and casing. The original shim washer value will give
correct torque peak position unless major components
have been replaced.
Procedure
88.With input coupling shaft toward the operator,
turn shaft fully counter-clockwise.
89.Check torque figures obtained from lock to lock
using torque wrench and spline socket
LRT-57-025.
90.Check also for equal engagement either side of
centre.Adjustments
91.Note where greatest figures are recorded
relative to steering position.If greatest figures are
not recorded across centre of travel (steering
straight-ahead), adjust as follows:
If torque peak occursbeforecentre position,addto
shim washer value; if torque peak occursaftercentre
position,subtractfrom shim washer value,
refer to
fitting valve and worm assembly
.
Shim washers are available as follows:
0.03mm, 0.07mm, 0.12mm and 0.24mm.
NOTE: Adjustment of 0.07mm to shim
value will move torque peak area by 1/4
turn on the shaft.
CAUTION: When reshimming valve and
worm, extreme caution must be exercised
to prevent seal damage during
reassembly.

STEERING
9
OVERHAUL Input shaft oil seal
92.Fit seal, lip side first, into housing. Use seal
saverLRT-57-016and seal installer
LRT-57-026. Note that seal is fitted to a depth of
4.75 - 5.00 mm from face of box.
93.Secure seal with circlip.
94.Smear inner lip of dirt excluder with PTFE
grease. Fit dirt excluder usingLRT-57-027.
When fitted correctly outer shoulder of excluder
is 4.00 - 4.50 mm from face of box, dimension X.
95.Remove drop arm. Smear inner lip of dirt
excluder with PTFE grease and refit, ensuring
outer lip is flush with casing.
96.With input shaft on centre, align assembly marks
on drop arm and steering box. Fit drop arm to
steering box using a new tab washer. Tighten to
176 Nm (130 lbf/ft),bend over tab.
97.Fit steering box
See Repair, Power Steering
Box
.

STEERING
1
SPECIFICATIONS, TORQUE REV: 05/99 TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Ball joint nuts 40..............................................................................................
Clamp bolt nuts 9...........................................................................................
Steering column bracket nuts 22....................................................................
Steering wheel nut 43.....................................................................................
Tie bar to mounting nut 110.............................................................................
Universal joint pinch bolt 25............................................................................
PAS box
Adjuster locknut 60.................................................................................
Drop arm nut 176....................................................................................
Sector shaft cover to steering box 75.....................................................
Steering box to chassis 81.....................................................................
Steering box fluid pipes 14mm thread 15...............................................
Steering box fluid pipes 16mm thread 20...............................................
Tie bar 81...............................................................................................
PAS pump
High pressure fluid pipe 20.....................................................................
Power steering pump mounting 35.........................................................
Pulley bolts, power steering pump 10....................................................
Hose clamp 3........................................................................................
Front mounting plate bolts 9..................................................................
PAS reservoir
Hose clamp 3........................................................................................
* Torque values below are for all screws and bolts used except for those that are specified otherwise.
METRIC Nm
M5 6......................................................................................................
M6 9......................................................................................................
M8 25.....................................................................................................
M10 45...................................................................................................
M12 90...................................................................................................
M14 105..................................................................................................
M16 180..................................................................................................
UNC / UNF
1/4 9......................................................................................................
5/16 24...................................................................................................
3/8 39.....................................................................................................
7/16 78...................................................................................................
1/2 90.....................................................................................................
5/8 136....................................................................................................

FRONT SUSPENSION
1
DESCRIPTION AND OPERATION DESCRIPTION
The front suspension design allows maximum wheel
travel and axle articulation providing good ground
clearance without loss of traction or directional
stability.
Long radius arms are fitted to the front axle and
provide maximum axle articulation which is vital for off
road performance. The radius arms are secured to
fabricated mounting brackets welded to the front axle.
Flexible rubber bushes are used on a stem end joint
to secure the rear of the radius arms to mountings on
the chassis cross member.
A panhard rod, which ensures that the front axle
remains centrally located, is fitted transversely and
also uses ferrule rubber bush mountings at both axle
and chassis locations.Two rubber bearing bushes, with retaining straps,
secure the rear of the anti-roll bar to the chassis
mountings, while bushed links support the front of the
bar to the front axle.
Conventional long travel coil springs and hydraulic
shock absorbers are used to control body movement
in all conditions. The shock absorbers are secured to
fabricated towers which are bolted to the chassis. The
upper and lower fixings use a single location stud with
flexible rubber bushes, support washers and securing
nuts. Retaining plates are used to secure the coil
springs to the fabricated towers and axle mountings.
Rubber bump stops are fitted underneath the chassis,
adjacent to the front road springs, and prevent
possible damage that could occur should there be
excessive axle to chassis movement.
Front suspension
1.Panhard rod
2.Radius arms
3.Coil springs
4.Shock absorber
5.Anti-roll bar

FRONT SUSPENSION
1
REPAIR SELF LOCKING NUTS
WARNING: Where self locking nuts are
removed, they must be replaced with new
nuts of same specification.
PANHARD ROD
Service repair no - 60.10.07.
Remove
1.Remove fixings at mounting arm.
2.Remove fixings at axle bracket.
3.Remove panhard rod.
4.Using a suitable length of steel tubing, press out
flexible bushes. Ensure tubing locates on outer
edge of bush and not on rubber inner.
Refit
5.Fit replacement bushes.
CAUTION: Apply pressure to outer edge of
bush, and not rubber inner.
6.Fit panhard rod to axle bracket and mounting
arm. Tighten fixings to
88 Nm (65 lbf/ft).
RADIUS ARM
Service repair no - 60.10.16.
Remove
1.Loosen road wheel retaining nuts.
2.Raise front of vehicle. Support chassis on stands
and remove wheel.
3.Support front axle weight with jack.
4.Remove radius arm to chassis side member
fixings.
5.Disconnect track rod at ball joint.

60FRONT SUSPENSION
2
REPAIRREV: 05/99
6.Remove fixings, radius arm to axle.
7.Lower radius arm front end to clear axle and
remove from vehicle.
8.Using suitable length of steel tubing, press out
flexible bushes.
Refit
9.Press in replacement bushes.
CAUTION: When pressing in new bushes
press on outer edge of bush and not
rubber inner.
10.Fit radius arm to axle mounting.
11.Fit track rod at ball joint.
12.Fit radius arm to chassis. Tighten bolts to
176
Nm (130 lbf/ft).
13.Fully tighten radius arm to axle fixings to197 Nm
(145 lbf/ft).
14.Fit road wheel, remove chassis stands and jack.
Tighten wheel nuts to correct torque:
Alloy wheels -
130 Nm (96 lbf/ft)
Steel wheels -100 Nm (80 lbf/ft)
Heavy duty wheels -170 Nm (125 lbf/ft)
FRONT SHOCK ABSORBER
Service repair no - 60.30.02.
Remove
1.Loosen road wheel retaining nuts.
2.Support chassis on stands and remove road
wheel.
3.Support axle weight with jack.
4.Remove shock absorber lower fixing and
withdraw cupwasher, rubber bush and seating
washer.
5.Remove four shock absorber bracket fixings.
6.Withdraw shock absorber and bracket assembly.
7.Withdraw lower seating washer, rubber bush and
cupwasher.
8.Remove fixings, shock absorber to mounting
bracket.
9.Withdraw mounting bracket.
10.Lift off top seating washer, rubber bush and
cupwasher.

FRONT SUSPENSION
3
REPAIR REV: 05/99 Refit
11.Assemble shock absorber components.
12.Position shock absorber, complete with bracket
and secure with 4 fixings.
13.Secure shock absorber lower fixing.
14.Fit road wheel, remove chassis stands and jack.
Tighten wheel nuts to correct torque:
Alloy wheels -
130 Nm (96 lbf/ft)
Steel wheels -100 Nm (80 lbf/ft)
Heavy duty wheels -170 Nm (125 lbf/ft)
FRONT ROAD SPRING
Service repair no - 60.20.11.
Remove
1.Remove front shock absorber
See Front
shock absorber
.
CAUTION: Avoid over stretching brake
hoses. If necessary, loosen hose
connector locknuts to allow hoses to
follow axle.
2.Lower axle sufficient to free road spring.
3.Withdraw road spring.
4.Withdraw shock absorber bracket securing ring.
Refit
5.Fit shock absorber bracket retaining ring. Retain
in position with a nut.
6.Position road spring and raise axle.
7.Remove nut retaining securing ring.
8.Fit front shock absorber
See Front shock
absorber
.

60FRONT SUSPENSION
4
REPAIR BUMP STOP
Service repair no - 60.30.10.
Remove
1.Remove fixings.
2.Remove bump stop.
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
remove and refit procedures are required, it may
be necessary to remove the undertray
See
CHASSIS AND BODY, Repair, Front undertray
.
Refit
3.Position bolts in slots in chassis brackets.
4.Fit bump stop, secure with washers and nuts.ANTI-ROLL BAR
Service repair no - 60.10.01
Remove
1.Mark for reassembly position of rubber bushes
on anti-roll bar.
2.Remove 4 nuts, bolts and washers securing both
anti-roll bar bush straps to chassis mounting
brackets.
3.Remove nuts, bolts, washers and rubber bushes
securing anti-roll bar to both links
4.Remove anti-roll bar.
Refit
5.Position bushes on anti-roll bar. Ensure split
points towards axle on RH bush and away from
axle on LH bush.
6.Fit anti-roll bar with two straps. To ensure correct
fit angled sides of bar should point down.
Loosely fit the bolts, washers and nyloc nuts.
7.Fit bolt, washers and rubber bushes. Using new
nuts fit anti-roll bar to links and tighten to
68Nm
(50 lbf/ft).
8.Tighten nuts securing straps to30Nm (22lbf/ft).

FRONT SUSPENSION
5
REPAIR ANTI-ROLL BAR LINKS
Service repair no - 60.10.04.
Remove
1.Remove 2 nuts, bolts, washers and rubber
bushes from ball joint links.
2.Remove cotter pin and loosen castellated nut a
few turns.
3.Release link joint using special tool18G 1063A
as shown.
4.Remove castellated nut and link.
Refit
5.Fit link and castellated nut. Ensure ball joint link
arm points up. Tighten nut to
40 Nm (30 lbf/ft)
and fit new cotter pin.
6.Align anti-roll bar to links.
7.Fit bolts, washers and rubber bushes using new
self locking nuts and secure anti-roll bar to links.
Tighten fixings to
68 Nm (50 lbf/ft).

FRONT SUSPENSION
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Anti-roll bar
- Strap nyloc nuts 30..............................................................................
- Ball link self lock nut 68........................................................................
- Castellated nut 40................................................................................
Drag link to axle 40.........................................................................................
Securing ring for mounting turret 14...............................................................
Radius arm to chassis 176...............................................................................
Panhard rod mounting arm to chassis 88.......................................................
Panhard rod to axle 88....................................................................................
Panhard rod to mounting bracket 88...............................................................
Tie bar to Panhard rod 110..............................................................................
Radius arm to axle 197....................................................................................